Collapsible carton

ABSTRACT

A folding carton formed from a blank of corrugated board, including first, second, third and fourth side walls hingedly connected by their edges to form a generally rectangular tubular enclosure, a bottom formed by at least two bottom walls hingedly connected to at least two of the side walls, and a top wall. The top wall is formed by first through fourth top cover flap hingedly connected at one edge to the first through fourth side wall respectively. Each of the top cover flaps is generally rectangular with the second top cover flap including ears extending from corners at the edge opposite the one edge and the first and third top cover flaps each including a notch corresponding to one of the ears. An adhesive is on one surface of the second top cover flap adjacent the opposite edge.

CROSS REFERENCE TO RELATED APPLICATION(S)

Not applicable.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

REFERENCE TO A MICROFICHE APPENDIX

Not applicable.

TECHNICAL FIELD

The present invention is directed toward cartons, and particularlytoward collapsible cartons formed from a blank of corrugated board.

BACKGROUND OF THE INVENTION AND TECHNICAL PROBLEMS POSED BY THE PRIORART

Cartons, boxes and containers formed from blanks of corrugated cardboardare widely used in the world for storing and for shipping materials.U.S. Pat. No. 4,291,828, for example, illustrates one cartonconfiguration which has been used, such configuration being particularlywell suited for uses in which it is desirable that the carton be capableof being automatically set up with minimal manual effort.

Given the widespread use of such cartons by disparate people, fromprofessionals who ship large amounts of products each day tograndmothers packing a few precious heirlooms for storage, it isimportant that such cartons not only be easy and quick to assemble andeasy to use, but also be reliable for shipping and/or storing manydifferent objects for many different purposes.

In most uses, particularly shipping, it is important that the cartons bereliably maintained in a secure closed configuration, thereby not onlyprotecting the contents inside the carton but also ensuring that thecontents remain in the carton even if it is moved around. To accomplishthis, a wide variety of techniques have been used to close the containertop, including crisscrossing the top flaps of the container, taping thetop flaps, and adhering the container flaps in a closed configurationthrough the use of adhesive applied to at least one of the flaps.

Moreover, particularly because such containers are usually secondary tothe item being stored or shipped (i.e., the people using the cartonsview them as a necessary material which is apart from the more valuableitem placed in the carton, with such item being of primary interest), itis important that the carton not only meet the ease of use andreliability requirements, but that it meet such requirements at minimumcost. Therefore, it is desirable to form such cartons of inexpensivematerials which may be easily processed with minimal waste of material.

Further, it is desirable that the cartons be able to be compactlyconfigured when not in use to minimize the cost of shipping and storageof the cartons themselves. To accomplish this, cartons are typicallyformed from blanks of suitable materials such as corrugated board andare provided in a collapsed condition to the end user. Of course, giventhe diversity of end users, this only heightens the need for a structurewhich may be easily changed to a container configuration from the flatconfiguration.

The present invention is directed toward overcoming one or more of theproblems set forth above.

SUMMARY OF THE INVENTION

In one aspect of the present invention, a corrugated container formedfrom a blank is provided, including first, second, third and fourth sidewalls hingedly connected by their edges to form a generally rectangulartubular enclosure, a bottom wall for the enclosure between lower edgesof the side walls; and a top wall. The top wall is formed by a first topcover flap hingedly connected at one edge to the first side wall, asecond top cover flap hingedly connected at one edge to the second sidewall, a third top cover flap hingedly connected at one edge to the thirdside wall, and a fourth top cover flap hingedly connected at one edge tothe fourth side wall. Each of the top cover flaps is generallyrectangular with the second top cover flap including ears extending fromcorners at the edge opposite the one edge and the first and third topcover flaps each including a notch corresponding to one of the ears.

In one form of this aspect of the present invention, the top cover flapshave a spacing S between the hinged one edge and the opposite edge, withspacing S being greater than half of the width of the first and thirdside walls by an amount generally equal to half of the spacing betweenedges of the ears.

In another form of this aspect of the present invention, the second topcover flap is a generally rectangular section and the ears extend fromopposite sides of the rectangular section, with the ears hingedlyconnected to the rectangular section.

In still another form of this aspect of the present invention, adhesiveis provided on one surface of the ears. In a further form, the adhesiveis a continuous strip of adhesive on the ears and adjacent the oppositeedge of the second top cover flap between the ears whereby the secondcover top flap is securable by the adhesive to the fourth cover top flapwith the ears securable by the adhesive to the first and third sidewalls. In a still further form, a liner is on the adhesive, where theliner is selectively removable to expose the adhesive for securing theears to the first and third side walls.

In yet another form of this aspect of the present invention, the topcover flaps have a spacing between the hinged one edge and the oppositeedge which is greater than half of the width of the first and third sidewalls.

In still another form of this aspect of the invention, the blank is cutwith a perforated connection between the ears and the first and thirdtop cover flaps. In a further form, punched out holes are between theears and the first and third top cover flaps.

In another aspect of the present invention, a folding carton formed froma blank of cardboard is provided, including first, second, third andfourth side walls hingedly connected by their edges to form a generallyrectangular tubular enclosure, a bottom formed by at least two bottomwalls hingedly connected to at least two of the side walls, and a topwall. The top wall is formed by a first top cover flap hingedlyconnected at one edge to the first side wall, a second top cover flaphingedly connected at one edge to the second side wall, a third topcover flap hingedly connected at one edge to the third side wall, and afourth top cover flap hingedly connected at one edge to the fourth sidewall. The second top cover flap edge opposite the second top cover flapone edge has a width greater than the second side wall, and an adhesiveis on one surface of the second top cover flap adjacent the oppositeedge.

In one form of this aspect of the invention, a liner is on the adhesiveand is selectively removable to expose the adhesive for securing thesecond top cover flap to the first and third side walls.

In another form of this aspect of the invention, the second top coverflap has ears extending from opposite sides of the second cover flapdefining the greater width. In a further form, the top cover flaps havea spacing between the hinged one edge and the opposite edge which isgreater than half of the width of the first and third side walls. In afurther form, the top cover flaps have a spacing S between the hingedone edge and the opposite edge, with the spacing S being greater thanhalf of the width of the first and third side walls by an amountgenerally equal to half of the spacing between edges of the ears. In astill further form, the second top cover flap includes a generallyrectangular portion and the ears extend from opposite sides of therectangular portion, and the ears are hingedly connected to therectangular portion. In still another further form, the adhesive is onone surface of the ears, and in a still further form, the adhesive is acontinuous strip of adhesive on the ears and adjacent the opposite edgeof the second top cover flap between the ears.

In still another form of this aspect of the invention, the blank is cutwith a perforated connection between the ears and the first and thirdtop cover flaps and, in a still further form, punched out holes arebetween the ears and the first and third top cover flaps.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view of a blank cut to form a carton according to thepresent invention;

FIG. 2 is a perspective view of an open-topped carton formed from theFIG. 1 blank;

FIG. 3 is a perspective view of the FIG. 2 carton, with the carton topclosed.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 illustrates a blank 10 cut to form a carton 14 according to thepresent invention as illustrated in FIGS. 2-3. The blank 10 may beproduced from corrugated board or the like of any suitable size andweight (depending on the size and strength required of the carton 14being produced) and is cut in the shape and form shown in FIG. 1. It isscored along various lines as described hereafter to define the severalwalls and flaps of the carton and to facilitate the bending of the blank10 to produce the finished product.

It should be appreciated that the blank 10 is cut from a generallyrectangular area of material, with the blank 10 being shaped so as tominimize cut off scraps/waste. This configuration also enables multipleblanks 10 to be cut from large pieces of material with minimal wastedmaterial between the adjacent blanks 10. Moreover, it should beappreciated that the top of the blank 10 (which is the novel area ofthis invention) is substantially rectangular, thereby effectivelyresulting in a minimum of wasted material at that area.

The main portion of the blank 10 is of generally rectangular shape andis provided with a plurality of transverse score lines designated bynumerals 20, 22, 24, and 26, thus outlining the main portions of thecarton 14 which consist of the side walls 30, 32, 34, 36. Forconvenience herein, those walls may be referred to as a front wall 30, arear wall 34 and two lateral walls 32, 36. The side walls 30, 32, 34, 36define the sides of the enclosure produced by carton 14 formed from theblank 10.

At one edge of the lateral wall 36 is a narrow flap 38 which is suitablysecured to the end of the front wall 30 (at the opposite end of theblank 10) whereby the enclosure of the carton 14 is defined on the sidesby four side walls 30, 32, 34, 36. In the illustrated embodiment, theenclosure is rectangular, with the front and rear walls 30, 34 widerthan the lateral walls 32, 36. (As used herein, the carton wall hingedlysecured to the top flap which is outermost when closed [as describedbelow] is referred to as the rear wall 34.) It should be appreciatedthat different dimensions could be used depending upon the size ofcarton desired. It is advantageous with the present invention that thelateral walls 32, 36 be narrower than, or at least not be significantlywider than, the front and rear walls 30, 34, although configurations inwhich the lateral walls are significantly wider than the front and rearwalls may still use the broad scope of the present invention.

In completing the carton, the flap 38 is bent on score line 26 and iscaused to contact the face of the front wall 30, and secured thereto bysuitable means such as glue, paste, staples, fasteners or the like. (Asillustrated in FIGS. 2-3, the flap 38 is secured to the outer face ofthe front wall 30, although it should be understood that it could alsoadvantageously be secured to the inner face of the front wall 30). Thus,a rectangular tubular enclosure 40 is formed which is capable of beingopened to the position shown in FIGS. 2-3, and may also be collapsed ina substantially flat condition. In the flat condition, the faces of theside walls 30, 32, 34, 36 (which form the interior of the container whenopened) are disposed with the front wall 30 and lateral wall 32 in oneplane which is substantially parallel to and in contact with rear wall34 and the other lateral wall 36 which are likewise in the same plane.The two sets of walls are connected by hinge connections provided at thebending points of the carton along score lines 22 and 26.

Score lines 50, 52, 54, 56 along the bottom edges of the side walls 30,32, 34, 36 hingedly connect bottom flaps 60, 62, 64, 66 which are usedto form the bottom of the carton 14. The bottom flaps 60, 62, 64, 66 asillustrated are known, having been disclosed in U.S. Pat. No. 4,291,828,the disclosure of which is fully incorporated herein by reference. Theseflaps 60, 62, 64, 66 may be suitably connected as illustrated in the'828 patent to allow for the carton to be changed between the open andflat conditions with the bottom flaps 60, 62, 64, 66 cooperating tosubstantially automatically change between a flattened position and aposition defining the bottom of the carton 14. It should be understood,however, that virtually any structure suitable for forming the bottom ofthe carton 14 could be used within the broad scope of the invention,with the illustrated flaps 60, 62, 64, 66 being merely one suitableexample, and therefore further explanation of those flaps 60, 62, 64, 66is not included herein.

In accordance with the present invention, the top wall of the carton 14is formed by top cover flaps 70, 72, 74, 76, each of which are hingedlyconnected along score lines 80, 82, 84, 86 to side walls 30, 32, 34, 36,respectively. Each of the top cover flaps 70, 72, 74, 76 are generallyrectangular in shape. However, the rear top cover flap 74 includes apair of parallel ears 90, 92 at its corners opposite its score line 84connection to the rear wall 34, with the ears 90, 92 being cut fromcorners of the adjacent lateral top cover flaps 72, 76.

It should be appreciated that a strip along the top of the rear coverflap 74 (at the location of the ears 90, 92) may be suitably reinforcedif desired to strengthen the overall carton 14 via the configuration ofthe top wall as described below.

It should also be appreciated that the location of the ears 90, 92, inaddition to providing the advantages further discussed below, may beaccomplished with only minimal removal of materials from the lateralcover flaps 72, 76 and, moreover, that material is removed from alocation where it is least needed. That is, it should be appreciatedthat when the carton 14 is opened to act as a container and the topflaps 70, 72, 74, 76 are closed as discussed below, the missing materialfrom the lateral cover flaps 72, 76 will be beneath the center portionof the rear cover flap 74, where virtually no strength is provided bythe lateral cover flaps 72, 76.

The top cover flaps 70, 72, 74, 76 are separated from one another bycuts 100, 102, 104. However, a perforated cut 106, 108 may beadvantageously provided to releasably connected the ears 90, 92 to thelateral top cover flaps 72, 76. As a result, when the carton 14 is in aflat condition, the ear 90 at the bend corresponding to score line 22between sides 32, 34 will bend with the lateral top cover flap 72 andthereby will not project out in a position in which it would besusceptible to damage. Punched out holes 110, 112 may be provided at theperforated connection of the ears 90, 92 to facilitate breaking of theperforated cut when the carton 14 is opened to function as a container.

A contact adhesive 120 may be suitably applied along the upper edge ofone side of the front top cover flap 74. A suitable protective strip 124(only partially shown in FIG. 1) may be applied over the adhesive 120.The protective strip 124 may be a suitable material, such as a silicontreated paper, which will adhere to the adhesive 120 but may be peeledtherefrom to expose the adhesive 120 when desired as described below.

FIGS. 2 and 3 show the carton 14 in an open configuration and illustratethe advantageous closing of the carton 14 according to the presentinvention, in which the top wall of the carton 14 is formed by foldingin the top cover flaps 70, 72, 74, 76. More specifically, the lateraltop cover flaps 72, 76 are folded in first, followed by the front coverflap 70. After removal of the protective strip 124 from the adhesive120, the rear cover flap 74 may be folded in so that the rectangularportion will overlie a portion of the front cover flap 70 and be securedthereto by the adhesive 120. Further, the ears 90, 92 will be bent downalong the sides of the carton 14 and be secured to the lateral walls 32,36 by the adhesive 120. The ears 90, 92 thus provide the particularadvantage of providing an adhesion between surfaces which isperpendicular to the front and rear cover flap connection, whichadhesion is extremely strong given that the extended length of theadhered surfaces is parallel to the direction of a normal opening forceapplied to the rear cover flap 74. Simply put, opening the carton 14while the ears 90, 92 are adhered to the lateral walls 30, 34 willrequire not only a force sufficient to separate the adhesion between thefront and rear cover flaps 70, 74 but also will require a forcesufficient to shear the adhesive along the length of the connectionbetween the ears 90, 92.

Perforations 130 may also be advantageously provided in the top coverflap 76 adjacent the ears 90, 92 to define a tear off strip (which mayadvantageously be suitably reinforced such as is known) to allow for thecarton 14 to be opened when closed by tearing through the top cover flap76 along a line between the perforations 130 adjacent to, but spacedfrom, the ears 90, 92.

It should also be appreciated that the height H of the top cover flaps70, 72, 74, 76 (particularly the front and rear top cover flaps 70, 72)may advantageously be sized so that:H=0.5(S+W _(E)), where, as illustrated in FIG. 1:

-   -   S=the spacing between the sides of the lateral walls 32, 36        (i.e., the width of the lateral walls), and    -   W_(E)=the width of the ears 90, 92.        Such a size ensures that the rear cover flap 74 will overlap the        front cover flap 70 by substantially the width of the ears 90,        92 whereby, when the top cover flaps are closed, a portion of        the front cover flap 70 having the width of the ears 90, 92 will        both be physically trapped beneath the rear cover flap 74 and        also adhered thereto by the width of the adhesive 120 on the        rear cover flap 74 between the ears 90, 92. Moreover, the sides        of the front cover flap 70 will be trapped between the ears 90,        92, thereby protecting against the carton 14 potentially        twisting out of its rectangular shape.

From the foregoing disclosure, it should be evident that the novelcarton 14 as described herein may be assembled in a minimum time,thereby substantially reducing the cost of assembly and storage.Moreover, the assembly may be accomplished simply and easily, with theuse of the top cover flaps 70, 72, 74, 76 being virtually self evidentto even the most inexperienced user.

Still other aspects, objects, and advantages of the present inventioncan be obtained from a study of the specification, the drawings, and theappended claims. It should be understood, however, that the presentinvention could be used in alternate forms where less than all of theobjects and advantages of the present invention and preferred embodimentas described above would be obtained.

1. A corrugated container formed from a blank, comprising: first,second, third and fourth side walls hingedly connected by their edges toform a generally rectangular tubular enclosure; a bottom wall for saidenclosure between lower edges of the side walls; and a top wall formedby a first top cover flap hingedly connected at one edge to the firstside wall, a second top cover flap hingedly connected at one edge to thesecond side wall, a third top cover flap hingedly connected at one edgeto the third side wall, a fourth top cover flap hingedly connected atone edge to the fourth side wall, wherein each of said top cover flapsis generally rectangular with said second top cover flap including earsextending from corners at the edge opposite the one edge and said firstand third top cover flaps each including a notch corresponding to one ofthe ears.
 2. The corrugated container of claim 1, wherein said top coverflaps have a spacing S between said hinged one edge and the oppositeedge, wherein spacing S is greater than half of the width of the firstand third side walls by an amount generally equal to half of the spacingbetween edges of the ears.
 3. The corrugated container of claim 1,wherein said second top cover flap comprises a generally rectangularsection and said ears extend from opposite sides of said rectangularsection, and said ears are hingedly connected to said rectangularsection.
 4. The corrugated container of claim 1, further comprisingadhesive on one surface of said ears.
 5. The corrugated container ofclaim 4, wherein said adhesive comprises a continuous strip of adhesiveon said ears and adjacent said opposite edge of said second top coverflap between said ears whereby said second cover top flap is securableby said adhesive to said fourth cover top flap with said ears securableby said adhesive to said first and third side walls.
 6. The corrugatedcontainer of claim 4, further comprising a liner on said adhesive, saidliner being selectively removable to expose said adhesive for securingsaid ears to said first and third side walls.
 7. The corrugatedcontainer of claim 1, wherein said top cover flaps have a spacingbetween said hinged one edge and the opposite edge which is greater thanhalf of the width of the first and third side walls.
 8. The corrugatedcontainer of claim 1, wherein said blank is cut with a perforatedconnection between said ears and said first and third top cover flaps.9. The corrugated container of claim 8, further comprising punched outholes between said ears and said first and third top cover flaps.
 10. Afolding carton formed from a blank of corrugated board, comprising:first, second, third and fourth side walls hingedly connected by theiredges to form a generally rectangular tubular enclosure; a bottom formedby at least two bottom walls hingedly connected to at least two of saidside walls; and a top wall formed by a first top cover flap hingedlyconnected at one edge to the first side wall, a second top cover flaphingedly connected at one edge to the second side wall, a third topcover flap hingedly connected at one edge to the third side wall, afourth top cover flap hingedly connected at one edge to the fourth sidewall, wherein the second top cover flap edge opposite said second topcover flap one edge has a width greater than said second side wall; andan adhesive on one surface of said second top cover flap adjacent saidopposite edge.
 11. The folding carton of claim 10, a liner on saidadhesive, said liner being selectively removable to expose said adhesivefor securing said second top cover flap to said first and third sidewalls.
 12. The folding carton of claim 10, wherein said second top coverflap has ears extending from opposite sides of said second cover flapdefining said greater width.
 13. The folding carton of claim 12, whereinsaid top cover flaps have a spacing between said hinged one edge and theopposite edge which is greater than half of the width of the first andthird side walls.
 14. The folding carton of claim 13, wherein said topcover flaps have a spacing S between said hinged one edge and theopposite edge, wherein spacing S is greater than half of the width ofthe first and third side walls by an amount generally equal to half ofthe spacing between edges of the ears.
 15. The folding carton of claim12, wherein said second top cover flap includes a generally rectangularportion and said ears extend from opposite sides of said rectangularportion, and said ears are hingedly connected to said rectangularportion.
 16. The folding carton of claim 12, wherein said adhesive is onone surface of said ears.
 17. The folding carton of claim 16, whereinsaid adhesive comprises a continuous strip of adhesive on said ears andadjacent said opposite edge of said second top cover flap between saidears.
 18. The folding carton of claim 10, wherein said blank is cut witha perforated connection between said ears and said first and third topcover flaps.
 19. The folding carton of claim 18, further comprisingpunched out holes between said ears and said first and third top coverflaps.